Dodge ZB 2005 User manual

SERVICE MANUAL
2005
ZB
NO PART OF THIS PUBLICATION MAY BE
REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM OR
BY ANY MEANS, ELECTRONIC, MECHANICAL,
PHOTOCOPYING, RECORDING, OR OTHERWISE,
WITHOUT THE PRIOR WRITTEN PERMISSION
OF DAIMLERCHRYSLER CORPORATION.
DaimlerChrysler Corporation reserves the right to make changes in design or
to make additions to or improvements in its products without imposing any
obligations upon itself to install them on its products previously manufactured.
Copyright © 2004 DaimlerChrysler Corporation
81-526-05015

FOREWORD
The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. Information describing the operation and use of standard and
optional equipment is included in the Owner’s Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain description, operation, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and compo-
nents. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group. The first page of the group has
a contents section that lists major topics within the group. If you are not sure which Group contains the infor-
mation you need, look up the Component/System in the alphabetical index located in the rear of this manual.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide
DaimlerChrysler Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When
replacing fasteners, always use the same type (part number) fastener as removed.
DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis,
repair methods, or vehicle wiring at any time without prior notice or incurring obligation.

GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
3Differential & Driveline
5Brakes
6Clutch
7Cooling
8A Audio/Video
8B Chime/Buzzer
8E Electronic Control Modules
8F Engine Systems
8G Heated Systems
8H Horn
8I Ignition Control
8J Instrument Cluster
8L Lamps
8N Power Systems
8O Restraints
8Q Vehicle Theft Security
8R Wipers/Washers
8W Wiring
9Engine
11 Exhaust System
13 Frame & Bumpers
14 Fuel System
19 Steering
21 Transmission/Transaxle
22 Tires/Wheels
23 Body
24 Heating & Air Conditioning
25 Emissions Control
Component and System Index
Service Manual Comment Forms (Rear of Manual)

GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
3Differential & Driveline
5Brakes
6Clutch
7Cooling
8A Audio/Video
8B Chime/Buzzer
8E Electronic Control Modules
8F Engine Systems
8G Heated Systems
8H Horn
8I Ignition Control
8J Instrument Cluster
8L Lamps
8N Power Systems
8O Restraints
8Q Vehicle Theft Security
8R Wipers/Washers
8W Wiring
9Engine
11 Exhaust System
13 Frame & Bumpers
14 Fuel System
19 Steering
21 Transmission/Transaxle
22 Tires/Wheels
23 Body
24 Heating & Air Conditioning
25 Emissions Control
Component and System Index
Service Manual Comment Forms (Rear of Manual)

INTRODUCTION
TABLE OF CONTENTS
page page
BODY CODE PLATE
DESCRIPTION ..........................1
E-MARK LABEL
DESCRIPTION ..........................1
FASTENER IDENTIFICATION
DESCRIPTION ..........................2
FASTENER USAGE
DESCRIPTION
FASTENER USAGE .....................4
THREADED HOLE REPAIR ...............4
INTERNATIONAL SYMBOLS
DESCRIPTION ..........................4
MANUFACTURE PLATE
DESCRIPTION ..........................5
METRIC SYSTEM
DESCRIPTION ..........................5
TORQUE REFERENCES
DESCRIPTION ..........................7
VECI LABEL
DESCRIPTION ..........................9
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION ..........................9
VEHICLE CERTIFICATION LABEL
DESCRIPTION .........................10
BODY CODE PLATE
DESCRIPTION
This vehicle does not require a Body Code Plate
due to limited optional equipment and colors.
E-MARK LABEL
DESCRIPTION
An E-mark Label (Fig. 1) is located on the rear
shut face of the driver’s door. The label contains the
following information:
•Date of Manufacture
•Month-Day-Hour (MDH)
•Vehicle Identification Number (VIN)
•Country Codes
•Regulation Number
•Regulation Amendment Number
•Approval Number
Fig. 1 E-MARK LABEL
1 - COUNTRY CODE
2 - REGULATION NUMBER
3 - APPROVAL NUMBER
4 - AMENDMENT NUMBER
ZB INTRODUCTION 1

FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts.
BOLT MARKINGS AND TORQUES - METRIC
Bolt Markings 8.8/8.9 10.9 12.9
Bolt Dia. N·m Ft. Lbs. N·m Ft. Lbs. N·m Ft. Lbs.
6 12 105* 14 120* 16 12
8 25 250* 32 23 38 28
10 54 40 60 45 74 55
12 95 70 108 80 135 100
14 155 115 175 130 216 160
16 243 180 324 210 324 240
* Inch Lbs.
BOLT MARKINGS AND TORQUES - U. S. CUSTOMARY
Bolt Markings Grade 5 Grade 8
Bolt Dia. N·m Ft. Lbs N·m Ft. Lbs
1/4 - 20 10 95* 14 125*
1/4 - 28 10 95* 17 150*
5/16 - 18 22 200* 30 270*
5/16 - 24 26 240* 33 300*
3/8-1640305540
3/8-2447356045
7/16-1468508865
7/16-2074559570
1/2 - 13 101 75 135 100
1/2 -20 115 85 150 110
9/16 - 12 135 105 182 135
9/16 - 18 155 115 202 150
5/8 - 11 202 150 263 195
5/8 - 18 215 160 284 210
3/4 - 10 230 170 297 220
3/4 - 16 236 175 304 225
7/8 - 14 405 300 540 400
* Inch Lbs.
2 INTRODUCTION ZB

FASTENER STRENGTH
ZB INTRODUCTION 3
FASTENER IDENTIFICATION (Continued)

FASTENER USAGE
DESCRIPTION
FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Fasteners and torque specifications references in
this Service Manual are identified in metric and SAE
format.
During any maintenance or repair procedures, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.
THREADED HOLE REPAIR
Most stripped threaded holes can be repaired using
a Helicoilt. Follow the vehicle or Helicoiltrecommen-
dations for application and repair procedures.
INTERNATIONAL SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following
International Control and Display Symbols Chart are
used to identify various instrument controls. The
symbols correspond to the controls and displays that
are located on the instrument panel.
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Wind screen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
4 INTRODUCTION ZB

MANUFACTURE PLATE
DESCRIPTION
The Manufacturer Plate (Fig. 2) is located in the
engine compartment on the passenger side rear cor-
ner of the hood. The plate contains five lines of infor-
mation:
1. Vehicle Identification Number (VIN)
2. Gross Vehicle Mass (GVM)
3. Gross Train Mass (GTM)
4. Gross Front Axle Rating (GFAR)
5. Gross Rear Axle Rating (GRAR)
METRIC SYSTEM
DESCRIPTION
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million.
The following chart will assist in converting metric
units to equivalent English and SAE units, or vise
versa.
CONVERSION FORMULAS AND EQUIVALENT VALUES
MULTIPLY BY TO GET MULTIPLY BY TO GET
in-lbs x 0.11298 = Newton Meters
(N·m) N·m x 8.851 = in-lbs
ft-lbs x 1.3558 = Newton Meters
(N·m) N·m x 0.7376 = ft-lbs
Inches Hg
(60° F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches
Feet x 0.3048 = Meters (M) M x 3.281 = Feet
Yards x 0.9144 = Meters M x 1.0936 = Yards
mph x 1.6093 = Kilometers/Hr.
(Km/h) Km/h x 0.6214 = mph
Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph
Kilometers/Hr.
(Km/h) x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h)
Fig. 2 MANUFACTURER PLATE
ZB INTRODUCTION 5

METRIC CONVERSION CHART
6 INTRODUCTION ZB
METRIC SYSTEM (Continued)

COMMON METRIC EQUIVALENTS
1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters
1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers
Refer to the Metric Conversion Chart to convert
torque values listed in metric Newton- meters (N·m).
Also, use the chart to convert between millimeters
(mm) and inches (in.).
TORQUE REFERENCES
DESCRIPTION
Individual Torque Charts appear within many or
the Groups. Refer to the Standard Torque Specifica-
tions Chart for torque references not listed in the
individual torque charts.
ZB INTRODUCTION 7
METRIC SYSTEM (Continued)

TORQUE SPECIFICATIONS
8 INTRODUCTION ZB
TORQUE REFERENCES (Continued)

VECI LABEL
DESCRIPTION
All models have a Vehicle Emission Control Infor-
mation (VECI) Label. Chrysler permanently attaches
the label in the engine compartment. It cannot be
removed without defacing information and destroying
the label.
The label contains the vehicle’s emission specifica-
tions and vacuum hose routings. All hoses must be
connected and routed according to the label.
VEHICLE IDENTIFICATION
NUMBER
DESCRIPTION
The Vehicle Identification Number (VIN) is located
on the upper left corner of the instrument panel,
near the left windshield pillar (Fig. 3). The VIN con-
sists of 17 characters in a combination of letters and
numbers that provide specific information about the
vehicle. Refer to VIN Code Breakdown table for
decoding information.
VIN CODE BREAKDOWN
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1 = Manufactured By DaimlerChrysler Corpora-
tion
2 Make B = Dodge
3 Vehicle Type 3 = Passenger Car
4 Passenger Safety J = Restraint System Air Bags Front Next Gen-
eration Multi-Stage
5 Car Line Z = ZB/SRT-10 passenger car
6 Series 6 = Sport
7 Body Style 5 = 2 Door Convertible
8 Engine Z = 8.3L V10 Cyl. SFI Gasoline
9 Check Digit 0 through 9 or X
10 Model Year 5 = 2005
11 Assembly Plant V = Conner Ave. Assembly
12 through 17 Sequence Number 6 digit number assigned by assembly plant.
Fig. 3 VEHICLE IDENTIFICATION NUMBER
1 - RIVET
2 - VEHICLE IDENTIFICATION NUMBER (VIN)
3 - BODY ASSEMBLY
ZB INTRODUCTION 9

VIN CHECK DIGIT
To protect the consumer from theft and possible
fraud the manufacturer is required to include a
Check Digit at the ninth position of the Vehicle Iden-
tification Number. The check digit is used by the
manufacturer and government agencies to verify the
authenticity of the vehicle and official documenta-
tion. The formula to use the check digit is not
released to the general public.
VEHICLE CERTIFICATION
LABEL
DESCRIPTION
A vehicle certification label is attached to the rear
shutface of the driver’s door (Fig. 4). This label indi-
cates date of manufacture (month and year), Gross
Vehicle Weight Rating (GVWR), Gross Axle Weight
Rating (GAWR) front, Gross Axle Weight Rating
(GAWR) rear and the Vehicle Identification Number
(VIN). The Month, Day and Hour of manufacture is
also included.
All communications or inquiries regarding the
vehicle should include the Month-Day-Hour and
Vehicle Identification Number.
Fig. 4 VEHICLE CERTIFICATION LABEL - TYPICAL
10 INTRODUCTION ZB
VEHICLE IDENTIFICATION NUMBER (Continued)

LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
INTERNATIONAL SYMBOLS
DESCRIPTION ..........................1
PARTS & LUBRICANT RECOMMENDATION
DESCRIPTION
LUBRICANT RECOMMENDATIONS .........1
FLUID TYPES .........................2
FLUID TYPES
DESCRIPTION
ENGINE OIL ..........................2
ENGINE COOLANT .....................3
AXLE ................................4
POWER STEERING FLUID ...............4
MANUAL TRANSMISSION ................4
FLUID CAPACITIES
SPECIFICATIONS
FLUID CAPACITIES .....................4
FLUID CAPACITIES - EXPORT ............4
FLUID FILL/CHECK LOCATIONS
DESCRIPTION ..........................4
LUBRICATION POINTS
DESCRIPTION ..........................4
MAINTENANCE SCHEDULES
DESCRIPTION
MAINTENANCE SCHEDULES .............4
HOISTING
STANDARD PROCEDURE - HOISTING .......10
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING . 10
TOWING
STANDARD PROCEDURE - TOWING ........11
VEHICLE STORAGE
STANDARD PROCEDURE
VEHICLE PREPARATION ................11
ENGINE COMPONENT PREPARATION .....11
FUEL SYSTEM PREPARATION ...........12
BRAKE SYSTEM PREPARATION ..........12
REAR AXLE PREPARATION .............12
WHEELS AND TIRES PREPARATION ......12
INTERIOR TRIM PREPARATION ..........12
BODY PREPARATION ..................12
RETURNING VEHICLE FROM LONG TERM
STORAGE ...........................13
INTERNATIONAL SYMBOLS
DESCRIPTION
DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid inspection and fill locations (Fig. 1).
PARTS & LUBRICANT
RECOMMENDATION
DESCRIPTION
LUBRICANT RECOMMENDATIONS
Chassis
Component Fluid, Lubricant, or Genuine Part
Steering Gear
& Linkage,
Ball Joints,
Prop Shafts &
Yokes, Wheel
Bearings
MoparTMulti-Purpose Lubricant
NLGI Grade 2 EP, GC-LB
Fig. 1 INTERNATIONAL SYMBOLS
ZB LUBRICATION & MAINTENANCE 0 - 1

Body
Component Fluid, Lubricant, and Genuine
Part
Hinges:
Door & Hood MoparTEngine Oil
Swing Gate MoparTMulti-Purpose Lube NLGI
Grade 2 EP, GC-LB
Latches: Door,
Hood/Safety
Catch, Swing
Gate
MoparTMulti-Purpose Lube NLGI
Grade 2 EP, GC-LB
Seat Regulator
& Track MoparTMulti-Purpose Lube NLGI Grade 2 EP, GC-LB
Lock Cylinders MoparTLock Cylinder Lube
FLUID TYPES
When service is required, DaimlerChrysler Corpo-
ration recommends that only Mopartbrand parts,
lubricants and chemicals be used. Mopartprovides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
Only lubricants bearing designations defined by
the following organization should be used to service a
Chrysler Corporation vehicle.
•Society of Automotive Engineers (SAE)
•American Petroleum Institute (API) (Fig. 2)
•National Lubricating Grease Institute (NLGI)
API QUALITY CLASSIFICATION
This symbol on the front of an oil container means
that the oil has been certified by the American Petro-
leum Institute (API) to meet all the lubrication
requirements specified by DaimlerChrysler Corpora-
tion.
GEAR LUBRICANTS
SAE ratings also apply to multigrade gear lubri-
cants. In addition, API classification defines the
lubricants usage. Such as API GL-5 and SAE 75W-
90.
FLUID TYPES
DESCRIPTION
ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
When service is required, DaimlerChrysler Corpo-
ration recommends that only Mopartbrand parts,
lubricants and chemicals be used. Mopartprovides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
Only lubricants bearing designations defined by
the following organization should be used.
•Society of Automotive Engineers (SAE)
•American Petroleum Institute (API)
•National Lubricating Grease Institute (NLGI)
•Association des Constructeurs Européens d’
Automobiles (European Automobile Manufacturers
Association) (ACEA)
API SERVICE GRADE CERTIFIED
DaimlerChrysler Corporation recommends a fully
synthetic API certified engine oil of the proper viscos-
ity grade for refill. 8.3L engine factory fill is Mobil 1t
10W-30.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. Use only engine oils with multi-
ple viscosities such as 5W-30 or 10W-30. These are
specified with a dual SAE viscosity grade which indi-
cates the cold-to-hot temperature viscosity range.
Select an engine oil that is best suited to your par-
ticular temperature range and variation (Fig. 3).
SYNTHETIC ENGINE OILS
The 8.3L engine comes from the factory with Mobil
1tsynthetic engine oil. A full synthetic API certified
engine oil of the proper viscosity grade is recom-
mended for refill.
Fig. 2 API Symbol
0 - 2 LUBRICATION & MAINTENANCE ZB
PARTS & LUBRICANT RECOMMENDATION (Continued)

ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for
8.3L engines. The designation of ENERGY CON-
SERVING is located on the label of an engine oil con-
tainer.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the label
of engine oil plastic bottles and the top of engine oil
cans (Fig. 4).
ENGINE OIL ADDITIVES/SUPPLEMENTS
The manufacturer does not recommend the addi-
tion of any engine oil additives/supplements to the
specified engine oil. Engine oil additives/supplements
should not be used to enhance engine oil perfor-
mance. Engine oil additives/supplements should not
be used to extend engine oil change intervals. No
additive is known to be safe for engine durability and
can degrade emission components. Additives can con-
tain undesirable materials that harm the long term
durability of engines by:
•Doubling the level of Phosphorus in the engine
oil. The ILSAC (International Lubricant Standard
Approval Committee) GF-2 and GF-3 standards
require that engine oil contain no more than 0.10%
Phosphorus to protect the vehicles emissions perfor-
mance. Addition of engine oil additives/supplements
can poison, from the added sulfur and phosphorus,
catalysts and hinder efforts to guarantee emissions
performance to 100,000 miles.
•Altering the viscosity characteristics of the
engine oil so that it no longer meets the require-
ments of the specified viscosity grade.
•
Creating potential for an undesirable additive com-
patibility interaction in the engine crankcase. Generally
it is not desirable to mix additive packages from differ-
ent suppliers in the crankcase; there have been reports
of low temperature engine failures caused by additive
package incompatibility with such mixtures.
ENGINE COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
protection and less boiling protection.
The cooling system is designed around the coolant.
The coolant must accept heat from engine metal, in
the cylinder head area near the exhaust valves and
engine block. Then coolant carries the heat to the
radiator where the tube/fin radiator can transfer the
heat to the air.
The use of aluminum cylinder blocks, cylinder heads,
and water pumps requires special corrosion protection.
MopartAntifreeze/Coolant, 5 Year/100,000 Mile For-
mula (MS-9769), or the equivalent ethylene glycol base
coolant with hybrid organic corrosion inhibitors (called
HOAT, for Hybrid Organic Additive Technology) is rec-
ommended. This coolant offers the best engine cooling
without corrosion when mixed with 50% Ethylene Gly-
col and 50% distilled water to obtain a freeze point of
-37°C (-35°F). If it loses color or becomes contaminated,
drain, flush, and replace with fresh properly mixed cool-
ant solution.
Fig. 3 Temperature/Engine Oil Viscosity
Fig. 4 API Certification Mark
ZB LUBRICATION & MAINTENANCE 0 - 3
FLUID TYPES (Continued)

The 5 Year/100,000 Mile Formula (orange in color)
and the Three Year Formula (green in color) MUST
NOT BE MIXED.
CAUTION: MoparTAntifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Doing so
will reduce the corrosion protection and may result
in premature water pump seal failure. If non-HOAT
coolant is introduced into the cooling system in an
emergency, it should be replaced with the specified
coolant as soon as possible.
AXLE
NOTE: DaimlerChrysler recommends using MoparT
lubricants or lubricants of equal quality.
•226RIA - MopartSynthetic Gear & Axle Lubri-
cant 75W-140, plus 4 ounces of MopartLimited Slip
Additive
POWER STEERING FLUID
The power steering fluid recommended is Mopart
Power Steering Fluid MS 5931. Transmission fluid
should not be used in the power steering.
MANUAL TRANSMISSION
NOTE: DaimlerChrysler recommends using MoparT
lubricants or lubricants of equal quality.
•Tremec T-56 - MopartSynthetic 75W85 Manual
Transmission Lubricant
FLUID CAPACITIES
SPECIFICATIONS
FLUID CAPACITIES
DESCRIPTION SPECIFICATION
Fuel Tank 70.0 L (18.5 gal.)
Engine Oil with Oil Filter 10.4 L (11.0 qts.)
Cooling System 15.1 L (16.0 qts.)
Transmission 3.8 L (4 qts.)
Differential Including
Additive 1.35 L (45 oz.)
Differential Additive 0.1 L (4 oz.)
Brake Fluid 0.3 L (7.5 oz.)
Windshield Washer 1 L (1 qt.)
FLUID CAPACITIES - EXPORT
DESCRIPTION SPECIFICATION
Fuel Tank 70.0 L (18.5 gal.)
Engine Oil with Oil Filter 10.4 L (11.0 qts.)
Cooling System 15.1 L (16.0 qts.)
Transmission 3.8 L (4 qts.)
Differential Including
Additive 1.35 L (45 oz.)
Differential Additive 0.1 L (4 oz.)
Brake Fluid 0.3 L (7.5 oz.)
Windshield Washer 4.7 L (5 qts.)
FLUID FILL/CHECK
LOCATIONS
DESCRIPTION
The fluid check/fill point locations are located in
each applicable service manual section.
LUBRICATION POINTS
DESCRIPTION
Lubrication point locations are located in each
applicable Sections.
MAINTENANCE SCHEDULES
DESCRIPTION
MAINTENANCE SCHEDULES
There are two maintenance schedules that show
the required service for your vehicle.
First is Schedule “B”. It is for vehicles that are
operated under the conditions that are listed below
and at the beginning of the schedule.
•Day or night temperatures are below 32° F (0°
C).
•Stop and go driving.
•Extensive engine idling.
•Driving in dusty conditions.
•Short trips of less than 10 miles (16 km).
•More than 50% of your driving is at sustained
high speeds during hot weather, above 90° F (32° C).
•Trailer towing.L
•Taxi, police, or delivery service (commercial ser-
vice).L
•Off-road or desert operation.
0 - 4 LUBRICATION & MAINTENANCE ZB
FLUID TYPES (Continued)

•If equipped for and operating with E-85
(ethanol) fuel.
NOTE: If ANY of these apply to you then change
your engine oil every 3,000 miles (5,000 km) or 3
months, whichever comes first and follow schedule
B of the “Maintenance Schedules” section of this
manual.
NOTE: If ANY of these apply to you then flush and
replace the engine coolant every 102,000 miles
(164,000 km) or 60 months, whichever comes first,
and follow schedule B of the (Maintenance Sched-
ules(section of this manual.
NOTE: Most vehicles are operated under the condi-
tions listed for Schedule (B(.
Second is Schedule “A”. It is for vehicles that are
not operated under any of the conditions listed under
Schedule 9B9.
Use the schedule that best describes your driving
conditions. Where time and mileage are listed, follow
the interval that occurs first.
NOTE: Under no circumstances should oil change
intervals exceed 6 months or 6,000 miles, which-
ever comes first.
CAUTION: Failure to perform the required mainte-
nance items may result in damage to the vehicle.
At Each Stop for Fuel
•Check the engine oil level about 5 minutes after
a fully warmed engine is shut off. Checking the oil
level while the vehicle is on level ground will
improve the accuracy of the oil level reading. Add oil
only when the level is at or below the ADD or MIN
mark.
•Check the windshield washer solvent and add if
required.
Once a Month
•Check tire pressure and look for unusual wear
or damage.
•Inspect the battery and clean and tighten the
terminals as required.
•Check the fluid levels of coolant reservoir, brake
master cylinder, power steering and transmission
and add as needed.
•Check all lights and all other electrical items for
correct operation.
At Each Oil Change
•Change the engine oil filter.
•Inspect the exhaust system.
•Inspect the brake hoses.
•Inspect the suspension components.
•Lubricate door hinges and check springs.
•Check the engine coolant level, hoses, and
clamps.
•Check power steering fluid level.
SCHEDULE B
Follow schedule “B” if you usually operate your
vehicle under one or more of the following conditions.
•Day or night temperatures are below 32° F (0°
C).
•Stop and go driving.
•Extensive engine idling.
•Driving in dusty conditions.
•Short trips of less than 10 miles (16 km).
•More than 50% of your driving is at sustained
high speeds during hot weather, above 90° F (32° C).
•Trailer towing.
•Taxi, police, or delivery service (commercial ser-
vice).
•Off-road or desert operation.
•If equipped for and operating with E-85
(ethanol) fuel.
NOTE: If ANY of these apply to you then change
your engine oil every 3,000 miles (5 000 km) or 3
months, whichever comes first and follow schedule
“B” of the (Maintenance Schedules(section of this
manual.
NOTE: IF ANY of these apply to you then flush and
replace the engine coolant every 102,000 miles
(164,000 km) or 60 months, whichever comes first,
and follow schedule B of the (Maintenance Sched-
ules(section of this manual.
ZB LUBRICATION & MAINTENANCE 0 - 5
MAINTENANCE SCHEDULES (Continued)